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    Advanced Product Quality Planning

    A structuredmethod of defining the steps (process) necessary to assure that aproduct satisfies the customer

    The goalof APQP is tofacilitate communication with everyone involved to

    ensure that all required steps are completed on time.

    EffectiveAPQP depends upon top management commitment and support to

    assure that customer satisfaction is achieved

    PlanningPlanning

    oncept!nitiation "Approval

    #esign $ #evelopment

    %alidation

    Production

    &eed'ac Assessment $ orrective Action

    ProgramApproval

    Prototype

    Pilot

    aunch

    Plan $#efine

    Program

    Product#esign $

    #ev.%erification

    Process#esign $

    #ev.%erification

    Product $Process

    %alidation

    Product

    Process

    Product " Process

    A!A* APQP $ trl Plan +eference *uide, Page -

    Advanced Product Quality Planning

    1

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    Advanced Product Quality Planning

    Phase/ !nputs $ 0utputs %oice of the ustomer

    1 2aret +esearch

    1 3istorical 4arranty and Quality!nformation

    1 Team E5perience

    6usiness Plan and 2areting

    7trategy

    Product8Process 6enchmar #ata

    Product8Process Assumptions

    Product +elia'ility 7tudies

    ustomer !nputs

    7ervice

    #esign *oals

    +elia'ility and Quality *oals Preliminary 6ill of 2aterial

    Preliminary Process &low hart

    Preliminary isting of 7pecial

    Product and Process

    haracteristics

    Product Assurance Plan

    2anagement 7upport

    Phase 1 Phase 2

    0utputs 'y #esign+esponsi'le Activity

    0utputs 'y Advanced

    Product Quality

    Planning Team

    #esign &2EA

    #&2 and #&A

    1#esign for 2anufactura'ility

    1#esign for Assem'ly

    #esign %erification

    #esign +eviews

    Prototype 6uild ontrol Plan

    Engineering #rawings (including 2ath data)

    Engineering 7pecifications

    2aterial 7pecifications

    #rawing and 7pecification hanges

    9ew equipment, tooling and

    facilities requirements

    7pecial product and processcharacteristics

    *age and testing equipment

    requirements

    Team feasi'ility commitment

    and management support

    7u'contractor 'uild

    7upplier 'uildPhase 3

    Pacaging 7tandards

    Product 8 Process Quality 7ystem +eview

    Process &low hart

    &loor Plan ayout

    haracteristics 2atri5

    Process &ailure 2ode and Effects

    Analysis

    Pre"aunch ontrol Plan

    Process !nstructions

    2easurement 7ystems Analysis Plan

    Preliminary Process apa'ility 7tudy Plan

    Pacaging 7pecifications Thin Critical Paths

    2

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    Advanced Product Quality Planning

    !nputs 8 0utputs " Phase :

    %oice of the ustomer

    ; 2aret +esearch

    ; 3istorical 4arranty and Quality

    !nformation

    ; Team E5perience

    6usiness Plan and 2areting

    7trategy

    Product8Process 6enchmar

    #ata

    Product8Process Assumptions

    Product +elia'ility 7tudies

    ustomer !nputs 7ervice

    #esign *oals

    +elia'ility and Quality *oals

    Preliminary 6ill of 2aterial

    Preliminary Process &low hart Preliminary isting of 7pecial

    Product and Process haracteristics

    Product Assurance Plan

    2anagement 7upport

    Phase 1

    Phase 1 Inputs

    Phase 1 Outputs (= Phase 2 Inputs)

    3

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    Advanced Product Quality Planning

    !nputs 8 0utputs " Phase - 2P3 A'ov e >- 2P3

    7teering wheel spoes not correct ly positioned when f ront wheels st reight

    0ther steering and handling pro'lems. Please descri'e.

    Advanced Product Quality Planning

    3istorical 4arranty and Quality !nformation

    @Things gone

    4rong reports 4arranty reports

    apa'ility

    indicators

    7upplier plant

    internal qualityreports

    Pro'lem

    resolution reports

    ustomer plant

    returns and

    reCections

    &ield return

    product analysis

    Tell us a'out any trou'les you have had with the vehicle. 2ar a B in each

    'o5 ne5t to any item you have had trou'le with.

    *teri&r Paint

    Things -&ne .r&ng

    /teering ' +an,ling

    10

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    &ramewor for quality plan

    2ay place constraints on timing, cost, investment,

    positioning, +$# resources

    7trategy defines target customer, ey sales points,

    ey competitors 740T

    17trengths

    14eanesses

    10pportunities1Threats

    0ld vs. 9ew

    13ow deep and how far to go

    Advanced Product Quality Planning

    6usiness Plan " 2areting 7trategy

    11

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    A requirement of Q7 D para. >.:

    Provides inputs to esta'lish performance targets

    2ust address ey process(es)

    2ust 'e measura'le

    2ethods for successful 'enchmaringF1!dentify appropriate 'enchmar(s)

    1&ind reason for gap 'etween your status and 'enchmar

    1#evelop a plan for closing gap, meeting or e5ceeding

    'enchmar

    Advanced Product Quality Planning

    Product " Process 6enchmar#ata

    12

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    Assumptions

    1&eatures

    1#esign

    1Process concepts

    1Technical innovations

    1Advanced materials1+elia'ility assessments

    19ew technology

    #ocument assumptions as part of proCect plan

    ?tiliGe as inputs to plan

    onsider alternate paths in case assumptions do not

    play out

    Advanced Product Quality Planning

    Product " Process Assumptions

    13

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    &requency of repairs or replacements within

    designated time period(s)1+epair or Throw"awayH

    1+? evel (ine +eplacea'ility ?nit)

    ong range relia'ility and8or dura'ility tests

    7tudies can 'e %E+I costly and lengthy1E#TP (Environmental #esign riteria Test Plan)

    Advanced Product Quality Planning

    Product +elia'ility 7tudies

    0T = 0eanTie eteen ailures

    0TO = 0eanTie eteen Overhaul0T% = 0eanTie eteen %eplaceent

    Market Share

    Durailityailures

    14

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    9e5t users provide information a'outneeds and e5pectations

    Possi'ility of previous conducted

    reviews and studies ?sed to develop measure of customer

    satisfaction

    Advanced Product Quality Planning

    ustomer !nputs

    15

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    Advanced Product Quality Planning

    !nter"+elationships

    Q07

    &2EA

    &TA

    +&TA

    APQP

    #0E

    Process

    !mprovemen

    t

    ontrol

    Plan

    7P

    Tools

    J"# Pr&le

    /&lving

    usiness

    Quality

    O5ectives

    Pr&le

    Preventi&n

    Q

    7pecial 8 ritical

    haracteristics

    ustomer 7pecified

    7pecial 8 ritical

    haracteristics

    16

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    Advanced Product Quality Planning

    +elationships

    ustomer+equirements

    #&2EA P&2EA 4arrantontrol Plan

    7tructuralonceptual 4arrant 7ample

    PPAP

    Product ondition

    Time

    17

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    Advanced Product Quality Planning

    Typical Automotive Trilogy #evelopment

    Pr&cess l& Diagra(Inclu,es A"" Pr&cesses)

    Pr&cess 0A

    (On A"" Pr&cesses)

    Pr&cess C&ntr&l Plan(Critical Pr&cesses r& 0A)

    Design 0A(On Inten,e, 6se)

    APQP Tieline

    7ome Elements may

    'e !ncluded 0n

    Critical Characteristics' Characteristic C&ntr&l Issues

    Critical Characteristics

    ' ailure ects Issues

    CC 0atri*

    ustomer

    +equirements(drawing, +&Q, etc.),

    Iour company/s

    internal design 8

    process

    requirements

    18

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    Advanced Product Quality Planning

    #ocument ins

    Pr&cess l& Chart0peration 9um'er

    Product8Process haracteristic

    !ncoming 7ources of %ariation

    (%ariation lass)

    .&r# Instructi&n0peration 9um'er

    P0A0peration 9um'er

    C&ntr&l Plan0peration 9um'erProduct8Process haracteristic

    !ncoming 7ources of %ariation

    (%ariation lass)

    The APQP manual cites

    these lins.!n some

    companies, these are

    not discrete documents.

    The intent is to ensure

    discrete documentsmatch.

    0peration 9um'er

    19

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    Advanced Product Quality Planning

    #ocument ritical Paths

    Pr&cess l& Chart

    Provides inputs to the Process &2EA and may provide inputs to the wor instruction.

    .&r# Instructi&n

    P0A

    C&ntr&l Plan

    D0A2ay or may not identify

    an input to the Process&2EA

    Provides input to control plan 'ased upon a ris analysis.

    Deine All Critical 7

    /pecial

    Characteristics

    20

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    Advanced Product Quality Planning

    Automotive Process &2EAProcess &ailure 2ode And Ef f ects Analy sis ow " 3igh

    ProcessF 0utside 7uppliers Af f ectedF EngineerF : " :

    Primary Process +esponsi'ility F 2odel Iear8%ehicle(s)F Part 9um'erF

    0ther #iv . 0r People !nv olv edF 7cheduled Production +eleasedF P&2EA #ateF +ev .

    Approva lsF Quality Assurance 2anager Quality Assurance Engineer

    0perations 2anager 7enior Adv isor

    Part 9ame0peration9um'er Proc es s & unc tion

    Potential &ailure2ode Potential Ef f ect s 0f & ailure Pot ent ial aus e 0f & ailure urrent ontrols 0

    ccured

    7everity

    #etection

    +P9 +ecommended

    Actions And 7tatusActions

    Taen+esponsi'le

    Activ ity

    7!+ Tae TPPE 4rong 2aterial &ragmented ontainer !nsuf f icient 7upplier ontrol 2aterial ertif ic ation : D < :J

    ontainer 2aterial 3eld !n ?npredicta'le #eploy ment !mproper 3andling +equired 4ith Each

    : 7torage Area 2isidentif ied 2aterial 7hipment

    +elease %erification

    0ut 0f 7 pec &ragm ent ed ont ainer 7upplier Proc es s ont rol Periodic Audit 0f = : = D

    2aterial ?npredicta'le #eploy ment 7upplier 2aterial

    ontaminated &ragmented ontainer 0pen 6o5es %isual !nspection : D K L=

    2aterial ?npredicta'le #eployment

    2aterial &ragmented ontainer Engineering hange +elease %erif ication : : K K

    omposition ?npredicta'le #eploy ment 7upplier hange *reen M0NM Tag

    hange ustomer 9otif ication

    < 2ov e To ?nreleased &ragmentation ?ntrained T0 hec &or *reen M0NM - : : -

    Approv ed ?ntrained Personnel Tag At Press

    7torage Trace ard

    hec ist

    Training

    = 3old !n Approv ed ontamination &ragmentation 0pen ontainers 6o5es Nept !n 7ealed : : = =

    7torage ?ntil Process Pro'lems 3ouseeeping 7torage Area ?ntil

    9eeded Area 2aintenance 9eeded

    6o5es ined 4ith

    Plastic

    iner 0n Pallets

    !nside 7torage

    P. 2. &acility

    21

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    Advanced Product Quality Planning

    Effects of hanging the Process &2EA

    P0AChange in Detecti&n

    Change in Occurrence

    Change in /everity

    .&r#Instructi&n

    Design Change

    C&ntr&l Plan

    And

    0r

    Other Acti&nA change in the severity &

    the eect & a p&tential

    pr&le can &nly e

    eecte, thr&ugh a ,esign

    change$

    .hen a#ing a change t& a ,&cuent8 it is ip&rtant t& c&nsi,er the eects & that change &n

    &ther ,&cuents$ Typically the engineering change syste in a c&pany an,7&r c&rrective acti&n

    syste ensures these &ccur$ ut this is n&t alays the case$ %evie y&ur c&pany engineering

    change pr&ce,ure 7 syste an, see i it ,&es s&$

    22

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    Advanced Product Quality Planning

    A orrective Action 7ystem

    These are s&e typical9chec#s: in the

    aut&&tive &rl, in

    resp&nse t& a

    c&rrective acti&n$ A

    change t& any &ne

    ,&cuent typically

    ,rives an ngineering

    Changehere the

    engineering changesysteis use, t&

    ensure that changes t&

    any &ne ,&cuent

    ensures appr&priate

    changes t& &thers$

    23

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    Advanced Product Quality Planning

    Product Specific FMEA Approach

    Pr&cess

    0A

    6rand spaning new,

    never 'efore product.

    6rand spaning new

    Process &2EA

    developed.

    Production Life

    ;ear 1

    &2EArevised in

    response to

    an J"#

    investigation

    &2EArevised in

    response to

    an J"#

    investigation

    Pr&cess

    0A

    opy of process &2EA

    from a similar product

    ;ear 1

    &2EArevised in

    response to

    an J"#

    investigation

    I do NOT recommend product specific FMEAs unless you really cannot

    segregate your products into families for some reason.

    &2EA

    revised in

    response to

    an J"#

    investigation

    ear !""! # $%& 'ody

    Inta(e manifold

    ear !"") # $%& 'ody

    Inta(e manifold

    ;ear 2

    24

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    Advanced Product Quality Planning

    urrent ontrol Plans $ &2EAs

    A Technology8&amily ontrol Plan 8 #evice &2EAfollows an entire flow for a technology/

    through a defined entity. This is in contrast with a process/ flow where there is an individual

    ontrol Plan for each piece of equipment or a manufacturing cell/(company definition). A

    Technology/ consists of many similardevices.

    Device&2EA 8 Techn&l&gy 7 ailyontrol Plan/ O a flow of a technology/ or device/

    Pr&cess &2EA covers an equipment set/ or cost 'loc/

    +ecommended 'y the &2EA Team

    A &r Other 0anuacturing ntity

    +eceiving/ in &A6 &2EAs consists of what the &A6 loos at when materials arrive. +eceived

    materials, such as gasses, liquid chemicals and related materials must 'e addressed. +egistrar

    interpretation Q- :8:< (AE"A:)F @...7o in effect, suppliers control plans will include wafers,

    gases, and chemicals...

    2achine orell :

    +eceiving/2achineor ell D PPAP)

    3A+ATE+!7T!, +!T!A, *2 #E&!9!T!09F 7ee Ney Product haracteristic. (P>D PPAP)

    3A+ATE+!7T!,NEI 09T+0 (Ns)F Those process parameters for which variation must 'e controlled around a target

    value to ensure that a significant characteristic is maintained at its target value. Ns require ongoing monitoring per an approved

    ontrol Plan and should 'e considered as candidates for process improvement. (P>D PPAP)

    3A+ATE+!7T!, NEI P+0#?T (NP)F Those product features that affect su'sequent operations, product function, or

    customer satisfaction. NPs are esta'lished 'y the customer engineer, quality representative, and supplier personnel from a review

    of the #esign and Process &2EA/s and must 'e included in the ontrol Plan. Any NPs included in customer"released engineering

    requirements are provided as a starting point and do not affect the supplier/s responsi'ility to review all aspects of the design,

    manufacturing process, and customer application and to determine additional NPs. (P>D PPAP)

    54

    haracteristics !!

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    haracteristics !! 3A+ATE+!7T!, P+0E77F ore team identified process varia'les (input varia'les) that have a cause and

    effect relationship with the identified Product haracteristic(s) which can only 'e measured at the time of occurrence.

    (L.=

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    haracteristics !!!

    3A+ATE+!7T!, 7A&ETI, 3+I7E+ #E&!9!T!09F 7pecifications which require special manufacturing control to

    assure compliance with hrysler or government vehicle safety requirements. (P- PPAP)

    3A+ATE+!7T!, 7!*9!&!A9T, 3+I7E+ #E&!9!T!09F 7pecial characteristics selected 'y the supplier through nowledge

    of the product and process. (Q7"D)

    3A+ATE+!7T!,7PE!AF Product and process characteristics designated 'y the customer, including governmental regulatory

    and safety, and8or selected 'y the supplier through nowledge of the product and process. (P:> APQP)

    3A+ATE+!7T!, 7PE!A, 3+I7E+ #E&!9!T!09 @#iamond U#VF 7pecifications of a component, material, assem'ly or

    vehicle assem'ly operation which are designated 'y hrysler as 'eing critical to function and having particular quality, relia'ility and

    dura'ility significance. (Q7"D)

    3A+ATE+!7T!, 7PE!A, 3+I7E+ #E&!9!T!09 @#iamond U#VF 7pecific critical characteristics that are process driven

    (controlled) and therefore require 7P to measure process sta'ility, capa'ility, and control for the life of the part. (Appendi5 Q7"

    D) $ (Appendi5 APQP)

    3A+ATE+!7T!, 7PE!A, 3+I7E+ #E&!9!T!09 @Pentagon UPVF imited to highlighting ritical characteristics on

    (Production) part drawings, tools and fi5ture, and tooling aid procedures where ongoing process control is not automatically

    mandated. (Appendi5 Q7"D) $ (Appendi5 APQP)

    3A+ATE+!7T!, 7PE!A, 3+I7E+ #E&!9!T!09 @7hield U7VF Engineering designated specifications or product

    requirements applica'le to component material, assem'ly operation(s) which require special manufacturing control to assure

    compliance with governmental vehicle safety, emissions, noise, or theft prevention requirements. (Appendi5 Q7"D) $

    (Appendi5 APQP)56

    haracteristics !%

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    haracteristics !% 3A+ATE+!7T!, 7PE!A, &0+# #E&!9!T!09 @ritical haracteristic U!nverted #eltaVF Those product

    requirements (#imensions, 7pecifications, Tests) or process parameters which can affect compliance with

    government regulations or safe %ehicle8Product &unction and which require specific producer, assem'ly, shipping or

    monitoring actions and inclusion on the ontrol Plan. (Appendi5 Q7"D) $ (Appendi5 APQP)

    3A+ATE+!7T!, 7PE!A, &0+# #E&!9!T!09 @7ignificant haracteristic " 7 U9oneVF Those product, process, and test

    requirements that are important to customer satisfaction and for which quality planning actions shall 'e included in the ontrol Plan.

    (Appendi5 Q7"D)

    3A+ATE+!7T!, 7PE!A, &0+# #E&!9!T!09 @7ignificant8haracteristic " 78 U9oneVF haracteristics that are important to

    the customer and that must 'e included on the ontrol Plan. (Appendi5 APQP)

    3A+ATE+!7T!, 7PE!A, *2 #E&!9!T!09 @&it8&unction U&8&VF Product characteristic for which reasona'ly anticipated

    variation is liely to significantly affect customer satisfaction with a product (other than 78) such as its fits, function, mounting or

    appearance, or the a'ility to process or 'uild the product. (Appendi5 Q7"D) $ (Appendi5 APQP)

    3A+ATE+!7T!, 7PE!A, *2 #E&!9!T!09 @7afety8ompliance U78VF Product characteristic for which reasona'lyanticipated variation could significantly affect customer the product/s safety or its compliance with government regulations (such asF

    flamma'ility, occupant protection, steering control, 'raing, etc. . .), emissions, noise, radio frequency interference, etc. . .

    (Appendi5 Q7"D)

    3A+ATE+!7T!, 7PE!A, *2 #E&!9!T!09 @7afety8ompliance U7VF Product characteristic for which reasona'ly anticipated

    variation could significantly affect customer the product/s safety or its compliance with government regulations (such asF

    flamma'ility, occupant protection, steering control, 'raing, etc. . .), emissions, noise, radio frequency interference, etc. . .

    (Appendi5 APQP)57

    haracteristics %

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    haracteristics %

    3A+ATE+!7T!, 7PE!A, *2 #E&!9!T!09 @7tandard U9oneVF Product characteristic for which reasona'ly

    anticipated variation is unliely to significantly affect a product/s safety, compliance with governmental regulations,

    fit8function. (Appendi5 Q7"D) $ (Appendi5 APQP)

    3A+ATE+!7T!, /PCIA", P+0E77 (e.g., C%ITICA"8 ;8 0AGO%8 /I-HIICAHT)F A process characteristic for which

    variation must 'e controlled to some target value to ensure that variation in a special product characteristic is maintained to its target

    value during manufacturing and assem'ly. (P-K &2EA)

    3A+ATE+!7T!, /PCIA", P+0#?TF ore team compilation of important product characteristics from all sources. All

    7pecial haracteristics must 'e listed on the ontrol Plan. (L.= :D APQP)

    3A+ATE+!7T!, /PCIA", P+0#?T (e.g., C%ITICA"8 ;8 0AGO%8 /I-HIICAHT)F A product characteristic for which

    reasona'ly anticipated variation could significantly affect a product/s safety or compliance with governmental standards or

    regulations, or is liely to significantly affect customer satisfaction with a product. (P-- &2EA)

    3A+ATE+!7T!, 7PE!A, T00!9*, 3+I7E+ #E&!9!T!09 @Pentagon UPVF ritical tooling sym'ol used to identify

    special characteristics of fi5tures, gages, developmental parts, and initial product parts. (Q7"D)

    09T+0 !TE2 PA+T, &0+# #E&!9!T!09F Product drawings8specifications containing ritical haracteristics. &ord #esign and

    Quality Engineering approval is required for changes to ontrol !tem &2EA/s and ontrol Plans. (Q7"D)

    58

    Phase : ProCect +eview

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    ProCect Title ustomer

    2odel8Iear Part #ate

    0ur advanced qual ity planning team has considered the foll owing questions in Phase :

    of our APQP process. The documents provided have 'een used as a 'asis for analyGingthe a'i lity to meet al l specifi ed requirements. All 90 answers are supported with attached

    com ments identifying our concerns and8or proposed changes to ena'le us to meet

    speci fied requirements.

    Ies 9o hecl ist !tem

    :. 3as historic al data and e5perience conc erning customer needs 'een consideredH

    . 3ave the product8process assumptions 'een i dentifi ed and chal langedH

    -. 3ave product relia'ility studies 'een conductedHL. 3ave there 'en appropriate customer inputs into the processH

    K. #o the design goals reflec t the data generatedH

    J. #o the qual ity and reli a'il ity goals reflect appropriate standardsH

    D. !s the prelimi nary 'ill of materials suffic ientl y thoroughH

    :. #oes the prelim inary process flow c hart relate to the primary 602 and

    produc t8process assumptionsH

    ::. Are all specia l product and process characteristics litedH

    :

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    Phase 1I Plan an, De(ine Pr&gra

    2anageme

    nt

    Purchasing

    Engineering

    Quality

    )a'oratory

    7ales

    Production

    3+

    2aintenance

    2aterials

    2!7

    0utput

    #esign *oals+elia'ility and Quality *oalsPreliminary 602Preliminary process flow chartPreliminary list of special product andprocess characteristics.

    Product assurance plan2anagement 7upport

    Advanced Product Quality Planning

    Phase : +esponsi'ility2atri5

    This form is on course dis60

    APQP Ph < P d t # i d # l t

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    PlanningPlanning

    #esign $ #evelopment

    %alidation

    Production

    &eed'ac Assessment $ orrective Action

    ProgramApproval

    Prototype

    Product#esign $

    #ev.%erification

    Product

    Process

    Product " Process

    Advanced Product Quality Planning

    APQP Phase

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    Advanced Product Quality Planning

    Phase < 0utputs

    0utputs 'y #esign +esponsi'le Activity

    0utputs 'y Advanced Product Quality

    Planning Team

    62

    0utputs 'y #esign +esponsi'le Activity

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    #esign &2EA

    #&2 and #&A1#esign for 2anufactura'ility

    1#esign for Assem'ly

    #esign %erification

    #esign +eviews Prototype 6uild " ontrol Plan

    Engineering #rawings (including 2ath data)

    Engineering 7pecifications

    2aterial 7pecifications

    #rawing and 7pecification hanges

    Advanced Product Quality Planning

    0utputs'y #esign +esponsi'le Activity

    63

    Additional 0 tp ts ' #esign +esponsi'le Acti it

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    ?pdated special characteristics list

    Prototype parts 'uild12ae " 6uy decisions

    1Parts inspection

    1Assem'ly of prototype(s)

    Prefera'ly manufacturing, not model shop

    1!nspection layout

    1Prototype validation testing

    +edesign as required and design review

    ?pdate #&2EA (and 7ystem evel &2EA if appropriate) &easi'ility report

    Advanced Product Quality Planning

    Additional 0utputs'y #esign +esponsi'le Activity

    64

    &2EAs

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    Advanced Product Quality Planning

    &2EAs

    65

    #&2EA

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    #isciplined analytical tool

    1Assess pro'a'ility of failure

    1Effect of failure

    2ust 'e continuallyupdated

    auses changes and8or additions to previously

    selected special product and8or process

    characteristics

    !f you do not have design control, you 2?7T(should)

    have customer #&2EA

    hec list (A!A* APQP 2anual Appendi5 A":)

    Advanced Product Quality Planning

    #&2EA

    66

    P&2EA E5ample

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    Process &ailure 2ode And Ef f ects Analy sis ow " 3igh

    ProcessF 0utside 7uppliers Af f ectedF EngineerF : " :

    Primary Process +esponsi'ility F 2odel Iear8%ehicle(s)F Part 9um'erF

    0ther #iv . 0r People !nv olv edF 7cheduled Production +eleasedF P&2EA #ateF +ev .

    Approv alsF Quality Assurance 2anager Quality Assuranc e Engineer

    0perations 2anager 7enior Adv isor

    Part 9ame0peration9 um 'er Proc es s &unc tion

    Potential &ailure2ode Pot ent ial Ef f ects 0f & ailure Pot ential aus e 0f & ailure urrent ontrols 0

    ccured

    7everity

    #etection

    +P9 +ecommended

    Actions And 7tatusActions

    Taen+esponsi'le

    Activ ity

    7!+ Tae TPPE 4rong 2aterial &ragment ed ontainer !nsuf f icient 7upplier ontrol 2aterial ertif ication : D < :J

    ontainer 2aterial 3eld !n ?npredicta'le #eploy ment !mproper 3andling +equired 4ith Each

    : 7torage Area 2isidentif ied 2aterial 7hipment

    +elease %erification

    0ut 0f 7 pec & ragment ed ont ainer 7upplier Proc ess ont rol Periodic Audit 0f = : = D

    2aterial ?npredicta'le #eploy ment 7upplier 2aterial

    ontaminated &ragmented ontainer 0pen 6o5es %isual !nspection : D K L=2aterial ?npredicta' le #eployment

    2aterial &ragmented ontainer Engineering hange +elease %erif ication : : K K

    omposition ?npredicta'le #eploy ment 7upplier hange *reen M0NM Tag

    hange ustomer 9otif ication

    < 2ov e To ?nreleased &ragmentation ?ntrained T0 hec &or *reen M0NM - : : -

    Approv ed ?ntrained Personnel Tag At Press

    7torage Trace ard

    hec ist

    Training

    = 3old !n Approv ed ontamination &ragmentation 0pen ontainers 6o5es Nept !n 7ealed : : = =

    7torage ?ntil Process Pro'lems 3ouseeeping 7torage Area ?ntil9eeded Area 2aintenance 9eeded

    6o5es ined 4ith

    Plastic

    iner 0n Pallets

    !nside 7torage

    P. 2. &acility

    Advanced Product Quality Planning

    P&2EA E5ample

    67

    #&2 and #&A

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    Advanced Product Quality Planning

    #&2and #&A #esign, concept,

    function and

    sensitivity

    (tolerancing)

    tomanufacturing

    variation

    2anufacturing

    and8or assem'ly

    process

    #imensional

    tolerances

    Performance

    requirements

    9um'er of

    components

    (comple5ity)

    Process

    adCustments

    2aterial

    handling

    68

    #esign %erification

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    !nspection methods

    Testing methods

    Ensure that all design outputs meet

    design input requirements1Alternate calculations

    1A#8math data

    1+eview design stage documents 'efore release

    Advanced Product Quality Planning

    #esign %erification

    69

    #esign +eviews Evaluations

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    #esign8functional requirement(s) and considerations

    &ormal relia'ility and confidence goals

    omponent8su'system8system duty cycles

    omputer simulation and 'ench test results

    #&2EA(s) +eview of the #&2 and #&A

    #esign of e5periments (#0E) and assem'ly 'uild

    variation results

    Test failures

    #esign verification progress

    2a582in 'uilds

    Advanced Product Quality Planning

    #esign +eviews " Evaluations

    70

    #esign +eview Tracing

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    Trac verification progress using a

    design verification plan and report (#%P$+

    " &ord $ hrysler)

    Product8process validation of

    components

    Advanced Product Quality Planning

    #esign +eview Tracing

    71

    Early Process &low #iagram

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    Advanced Product Quality Planning

    Early Process &low #iagram

    72

    Process &low #iagram E5ample

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    Pro#ess Flow Dia(ram &%%ro$ed *y+Part ,umber+ Date+ 4//9- .& Mana(er

    Part Des#ri%tion+ e$0 + 1 %erations Mana(er

    Pre%ared *y+ )enior &d$isor.& 3n(ineer

    )te% Fabri#ation

    Mo$e

    )tore

    Ins%e#t

    %eration Des#ri%tion Item 5ey Produ#t 1hara#teristi# Item 5ey 1ontrol 1hara#teristi#

    ! Move "OK" Vinyl Material 1.0 Material Specs 1.0 Material Certification Tag

    From Storage Area and

    Load Into Press.

    2 Auto Injection Mold Cover 2.0 Tearstrip In Cover 2.1 Tool Setup

    In Tool # 2.2 Machine Setup

    3.0 Hole Diameter In Cover 2.1 Tool Setup

    2.2 Machine Setup

    4.0 Flange Thickness In Cover 2.1 Tool Setup

    2.2 Machine Setup

    5.0 Pressure Control Protrusions 2.1 Tool Setup

    Height 2.2 Machine Setup

    - Visually Inspect Cover 6.0 Pressure Control Protrusions 2.1 Tool SetupFilled Out 2.2 Machine Setup

    7.0 Cover - Flash Free 2.1 Tool Setup

    2.2 Machine Setup

    8.0 Cover Filled Out 2.1 Tool Setup

    2.2 Machine Setup

    9.0 Free Of Foreign Material 2.2 Machine Setup

    Advanced Product Quality Planning

    g p

    73

    ontrol Plan 2ethodology

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    Aids in the manufacturing of products according to

    customer requirements

    Provide structured approaches

    ontain a written summary of the system used in

    minimiGing process and product variation

    &orms provided in the A!A* hand'oo are e5amples

    of how to document

    Alternate formats can 'e used if they contain

    necessary information

    2ust 'e maintained and used throughout the product

    life cycle

    Advanced Product Quality Planning

    ontrol Plan 2ethodology

    74

    ontrol Plan ?se

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    !nitialF To document and communicate

    initial process control

    9e5tF *uidance in controlling processes

    and to ensure product quality

    astFA living document reflecting

    current methods of control and

    measurement systems used

    Advanced Product Quality Planning

    ontrol Plan ?se

    75

    ontrol Plan

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    Ensure ontrol Plan is aligned to, and

    correlates with, #&2EA, Process &low,

    P&2EA

    ontrol 2ethods appropriate to

    variation type(s)

    !ncorporates essons earned,

    7tatistical #ata

    ?se A"J ontrol Plan checlist

    in APQP manual to evaluate

    Advanced Product Quality Planning

    ontrol Plan

    76

    Prototype 6uild ontrol Plan

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    A description of the dimensional

    measurements

    2aterial tests1&unctional tests that will occur during prototype

    'uild

    1#epending upon product comple5ity, several

    prototype 'uilds may 'e necessary and may

    require updates to the control plan

    Advanced Product Quality Planning

    Prototype 6uild ontrol Plan

    77

    7tandard ontrol Plan E5ample

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    ontrol Plan 9um'er Ney ontact 8 Phone #ate (0rig.) #ate (+ev.)

    Part 9o.8 atest hange 9o. ore Team ustomer Engineering Approval8#ate

    Part 9ame8#escription 7upplier8Plant Apoproval8#ate ustomer Quality Approval8#ate

    7upplier8Plant 7upplier ode 0ther Approval8date (!f +eqd) 0ther Approval8date (!f +eqd)

    haracteristics 2ethods

    Part8Process9um'er

    Process 9ame80peration

    #escription

    2achine,#evice,

    ig, Toolsfor 2fg. 9o. Product Process

    7pecialhar.lass

    Product8Process7pec8

    Tolerance

    Evaluation2easurement

    Tec hnique 7iGe&requ"ency

    ontrol2ethod

    +eactionPlan

    Advanced Product Quality Planning

    7tandard ontrol Plan E5ample

    This form is on course dis 78

    &ord/s #imensional ontrol Plan (#P)

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    Advanced Product Quality Planning

    &ord s #imensional ontrol Plan (#P)

    79

    ontrol Plan E5ample (*2)

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    Process ontrol Plan

    7upplier 9ameF 7upplier odeF Part 9um'erF7upplier +ep.F TelephoneF Part #escriptionF

    TitleF #ateF >8-8D= Engineering hange etterF Process Plan Ef fectiv e #ateF >8-8D=

    Ney Product ontrol haracterist ics *age 7tudy Process apa'ility Process Perf ormance ontrols

    (7hort Term apa'ilit y) (ong Term apa'ility )

    W:X WX W-X WLX WKX WJX WDX W:X W::X W:X W:-X W:LX W:KX W:JX

    !t em Ney P roduct Ney ontrol 0perat ion *age Att r.8 ast +$+ Y *age Proc ess Y Proces s p or #ev Proc ess Y Process p or #ev Ty pe 0f &req. 0f 0perat or Process

    haracteristic8 haracteristics #escription 0peration %aria'le #ate +$+ apa'ility apa'ility &rom Perf orm. Perf orm &rom ontrol !nspect. 7et"?p Audit

    7pec #ate Target89om. #ate Target89om. 2ethod *age 2ethod

    !nstruction and

    (Proced. ) &requency

    :. %iny l 2aterial hec Ev ery *reen M0NM

    7pec %endor 6o5 +elease,

    ert(s). Each 6o5

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    2ae "'uy decisions

    Part inspections

    Assem'le prototypes

    Perform layout inspection

    %alidation testing (4ho will do testingH)

    +edesign as required

    ?pdate #&2EA and 7&2EA if required

    Advanced Product Quality Planning

    Prototype 6uild

    81

    ustomer or 7upplier Engineering #rawings

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    +eview for special and8or critical characteristics

    +eview controlling drawings when engineering drawings

    are none5istent

    +eview drawings forF

    1#imensions for form, fit, function, dura'ility, government 7$+

    1ontrol or datum surfaces8locators for function gages and

    equipment

    1&easi'ility8compati'ility with industry standards

    ompati'ility of math data with two"way communications

    (.ritten aivers accepta'le)

    Advanced Product Quality Planning

    (including math data)

    82

    ustomer or 7upplier Engineering 7pecifications

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    +eview and understand controlling specifications

    !dentify functional, dura'ility and appearance

    requirements

    7hould defineF

    17ample siGe

    1&requency

    1Acceptance criteria

    0therwise, determined 'y supplier and included in

    control plan

    Advanced Product Quality Planning

    ustomer or 7upplier Engineering 7pecifications

    83

    2aterial 7pecifications

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    +eview 2aterial 7pecifications for

    7pecial haracteristics1Physical properties

    1Performance

    1Environmental

    13andling

    17torage

    !nclude in ontrol Plan

    Advanced Product Quality Planning

    2aterial 7pecifications

    84

    #rawing and 7pecifications hanges

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    hange control requirement applies

    Ensure proper communication

    Q7 D Element >.- #ocument and #ata

    ontrol/ applies(requires a hange ontrol system)

    Advanced Product Quality Planning

    #rawing and 7pecifications hanges

    85

    APQP Team 0utputs

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    Advanced Product Quality Planning

    APQP Team 0utputs

    9ew equipment, tooling and facilities

    requirements

    7pecial product and process characteristics

    *age and testing equipment requirements

    Team feasi'ility commitment and managementsupport

    7u'contractor 'uild

    7upplier 'uild

    86

    9ew Equipment, Tooling and &acilities +equirements

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    Advanced Product Quality Planning

    q p , g q

    Preliminary identification of new equipment, tooling

    and facilities

    Address these items on the timing chart

    Address capa'ility requirements

    Esta'lish delivery times omplete chec list in A!A* APQP $ ontrol Plan reference manual

    Appendi5 A"=

    87

    7pecial Product and Process haracteristics ist

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    Advanced Product Quality Planning

    p

    ?pgrade preliminary list started in Phase : from

    information gathered through review anddevelopment of design features

    1Additional sources

    #&2EA

    7&2EA if applica'le

    P&2EA

    Previous history

    2ust 'e on control plans for prototype, pre"launch

    and production

    isting should 'e a team consensus

    These ay &verlap

    88

    *ageand Testing Equipment +equirements

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    Advanced Product Quality Planning

    g g q p q

    Preliminary identification of inspection, test and

    measurement equipment

    +equirements on timing chart

    1omplete in time to conduct measurement

    systems analysis1Equipment 'uilder

    1Pilot 'uild

    1Production trial run

    89

    Team &easi'ility, ommitment and 2anagement 7upport

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    Advanced Product Quality Planning

    y g pp

    Team feasi'ility commitment

    omplete program review chec list, includingF

    1#esign feasi'ility

    1an 'e manufactured, assem'led, tested and pacaged

    1an 'e delivered in the right quantities on schedule at accepta'le

    cost

    1+eview design information chec list in A!A* APQP +eference manual Appendi5 A" chec list

    Advanced Product Quality Planning

    101

    Process &low hart

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    ?pdate process flow chart

    (E5ample in A!A* APQP +eference manual Appendi5 A"L)

    #escri'es current or proposed process flow

    ?sed to analyGe sources of variation

    3elps analyGe total process

    9eeded for process &2EA, characteristics matri5 and

    control plan +eference A!A* APQP +eference manual Appendi5 A"L chec list

    Advanced Product Quality Planning

    102

    Pro#ess Flow Dia(ram

    Process &low #iagram E5ample

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    Pro#ess Flow Dia(ram &%%ro$ed *y+Part ,umber+ Date+ 4//9- .& Mana(er

    Part Des#ri%tion+ e$0 + 1 %erations Mana(er

    Pre%ared *y+ )enior &d$isor.& 3n(ineer

    )te% Fabri#ation

    Mo$e

    )tore

    Ins%e#t

    %eration Des#ri%tion Item 5ey Produ#t 1hara#teristi# Item 5ey 1ontrol 1hara#teristi#

    ! Move "OK" Vinyl Material 1.0 Material Specs 1.0 Material Certification Tag

    From Storage Area and

    Load Into Press.

    2 Auto Injection Mold Cover 2.0 Tearstrip In Cover 2.1 Tool Setup

    In Tool # 2.2 Machine Setup

    3.0 Hole Diameter In Cover 2.1 Tool Setup

    2.2 Machine Setup

    4.0 Flange Thickness In Cover 2.1 Tool Setup

    2.2 Machine Setup

    5.0 Pressure Control Protrusions 2.1 Tool Setup

    Height 2.2 Machine Setup

    - Visually Inspect Cover 6.0 Pressure Control Protrusions 2.1 Tool SetupFilled Out 2.2 Machine Setup

    7.0 Cover - Flash Free 2.1 Tool Setup

    2.2 Machine Setup

    8.0 Cover Filled Out 2.1 Tool Setup

    2.2 Machine Setup

    9.0 Free Of Foreign Material 2.2 Machine Setup

    Advanced Product Quality Planning

    103

    &loor Plan ayout

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    #etermine accepta'ility of inspection and test points

    ontrol chart location(s) %isual aides

    !nterim repair stations

    (rewor)

    9onconforming material storage

    Neyed to material flow and control plan

    +eference A!A* APQP +eference manual Appendi5 A"-

    Advanced Product Quality Planning

    y

    104

    haracteristics2atri5

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    #isplays relationship 'etweenF

    1Process parameter

    12anufacturing stations +eference A!A* APQP +eference manual Appendi5 6, page J 0utputs

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    Production trial run

    2easurement system evaluation(complete)

    Preliminary process capa'ility study

    Production part approval

    Production validation testing

    Pacaging evaluation

    Production control plan

    Quality planning sign"off and management

    support

    Advanced Product Quality Planning120

    4or instructions for operating personnel

    Process !nstructions

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    4or instructions for operating personnel

    7ourcesF[ &2EAs

    [ ontrol plans

    [ Engineering drawings and specifications

    [ 2aterial specifications

    [ %isual standards

    [ !ndustry standards

    [ Process flow chart

    [ &loor plan layout

    [ haracteristic matri5

    [ Pacaging standards

    [ Process parameters

    [ Producer e5pertise

    [ 3andling requirements

    [ 0perators of process

    [ Accessi'le operators

    [ !nclude set"up parameters

    [ +eference Q7 D Element >.D Process ontrol/

    Advanced Product Quality Planning121

    2easurement 7ystems Analysis (27A)

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    omplete studies as defined in the 27A

    plan

    2inimum are those identified in the

    control plan

    7u'Cected to evaluation prior to or

    during production trial

    Advanced Product Quality Planning122

    27A 7tudies

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    2easurement uncertainty determined

    1*age +$+, 6ias, 7ta'ility, and inearity

    *age + $ + acceptance guidelines

    1U :Y accepta'le

    1:"=Y may 'e accepta'le, evaluate total variation1V=Y unaccepta'le, measuring system needs

    improvement

    %erify study performed correctly

    Advanced Product Quality Planning123

    2easurement 7ystems Analysis PlanEnsures *ageFinearity

    Accuracy

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    0easureent

    Instruent nvir&nent

    0aterial Inspect&r 0eth&,s

    7ample

    Preparation

    7ample

    ollection

    Paralla5

    +eproduci'ility

    Training

    Practice

    Ergonomic

    s

    Test 2ethod

    4ormanship

    7amples

    7tandards

    #iscrimination

    +epeata'ility

    6ias

    ali'ration

    inearity

    %i'ration

    ighting

    Temperature

    3umidityThese are some of the varia'les in a

    measurement system. 4hat others can

    you thin ofH

    Accuracy

    +epeata'ility

    +eproduci'ility

    orrelation for duplicate gages*ages may 'e needed prior to gage sign"off at su'contractor plant or any in"house

    pilot runs

    124

    2easurement Precision

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    Advanced Product Quality Planning

    ndica"es

    %&&

    %ecisi&n

    125

    % i i

    2easurement 6ias $ +epeata'ility

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    %ecise !,ecise

    Accua"e

    naccua"e!ias

    Y&u can c&ec" *& BiasY&u canNOc&ec" *& !,ecisi&n

    126

    Preliminary Process apa'ility7tudy Plan

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    2ust include characteristics identified in control

    plan &ew characteristics for simple component

    2any characteristics for comple5 product with

    many parts +eference A!A* &undamental 7P +eference 2anual

    Advanced Product Quality Planning127

    Pacaging Evaluation

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    Pacaging must conform to specifications

    developed 'y customer or supplier

    Assess protection of product

    ustomer specified pacaging must 'e

    evaluated 'y team

    Pilot or production trial run parts usually

    used in evaluation

    Advanced Product Quality Planning128

    Pacaging7pecifications

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    &or individual products

    ustomer pacaging

    *eneric standards where appropriate

    2ust ensure delivery quality ompati'le with all material handling

    equipment used

    Advanced Product Quality Planning129

    PPAP

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    Advanced Product Quality Planning

    APQP "aunch in,ers PPAP /uissi&n

    7u'"7et

    PPAP

    The n, Pr&,uct & APQPF

    130

    Production PartApproval Process

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    PPAP Production parts are manufactured at

    the production site using production

    tooling, gaging, equipment, operators,etc

    Parts from production run are analyGed.

    Test results and records from APQP aresu'mitted with Part 7u'mission 4arrant.

    Advanced Product Quality Planning131

    Purpose of PPAP

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    &or the supplier to demonstrateF

    ; All design records and specification.

    ; +equirements are properly understood.

    ;The process has the capa'ility to produceproduct that meets requirements.

    Advanced Product Quality Planning132

    Production Part Approval Process (PPAP)

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    Production Part Approval Process

    Parts produced at production site usingF

    1Production tooling1Production gages

    1Process

    10perators

    1Environment

    1Process settings

    &eeds

    7peeds

    ycle times

    Pressures

    Temperatures

    !ntent is to validate (prove) that products made using production equipment

    meet engineering requirements

    !f su'mission level is not nown, contact customer

    #efault level is =

    ustomer approval is required prior to quantity production

    +eference A!A* Production Part Approval Process reference manual

    Advanced Product Quality Planning133

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    Advanced Product Quality Planning134

    PPAP7cope

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    Production parts " generally = pieces/

    7ervice su'contractors " fulfill requirements

    6ul material

    !ncludes internaland e5ternalsources for

    information 7u'mission required prior to first production

    shipment

    PPAP 2anual 7ection !.= @ustomer 9otification and7u'mission +equirements (starting on page ::) for

    guidance

    Advanced Product Quality Planning135

    Application

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    Something

    Changed

    A!A* PPAP 2anual #efines

    4hen PPAP 7u'mission is+equired

    ; 9ew part

    ; orrection to discrepancy in previous

    su'mission; #esign or process change

    ; hange in source of su'contracted

    materials or services

    ; Transfer or rearrangement of tooling $

    equipment

    Advanced Product Quality Planning136

    2ethodology

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    Approver evaluates

    PPAP pacage.1evel - at supplier site

    Approver determine

    part su'missionstatus.

    9otify supplier and

    manufacturing of

    status.

    Advanced Product Quality Planning

    6uyer enters PPAP

    su'mission date onpurchase order.

    Approver determines

    su'mission level.1#efault level =

    1#efault level > for raw material

    7upplier su'mits PPAP

    1PPAPA.5lselectronicsu'mission (#elphi)

    137

    #&2EA

    7upplier #ata +eceived 4arrant

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    #&2EA

    ontrol Plan

    Early Production ontainment

    Plan (Pre"aunch ontrol Plan)

    Process capa'ility studies

    *age 2easurement 7ystemAnalysis

    a' Accreditation $ scope

    +estricted $ +eporta'le

    2aterials form !nterim 4orsheet, if required

    Advanced Product Quality Planning

    4arrant

    Appearance

    Approval +eport(AA+), as required

    7ample Parts

    Print8#esign +ecord

    Engineering hange

    #ocuments

    hec fi5tures8aids

    Process &low#iagram

    P&2EA

    138

    &low hart

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    inage of Product haracteristics from

    #&2EAto 0perational 7teps.

    0peration num'ers consistent with P&2EA,

    ontrolPlan, 0perator !nstructions.

    Ensure identification ofinspection and rewor.

    ?se A"L Process &low hartcheclist in APQP manual to

    evaluate.

    Advanced Product Quality Planning139

    #&2EA

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    Assess &easi'ility, +is, #esign !ntent

    !ssues onfirm 2anufacturing Process

    apa'ility onsidered

    &ocus on ritical haracteristics

    essons earned !ncorporated

    ?se A": #esign &2EA heclist

    in APQP 2anual to Evaluate

    Advanced Product Quality Planning140

    i ith #&2EA P &l

    P&2EA

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    inage with #&2EA, Process &low,

    ontrol Plan, 0perator !nstructions, etc #egree to which high +P9/s are

    addressed with preventive strategies

    Action Plans assigned,

    implemented, effectiveness

    assessed and +P9 recalculated

    ?se A"K Process &2EA

    checlist in APQP manual

    Advanced Product Quality Planning

    'P()&*+

    141

    Pre"aunch ontrol Plan

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    Early Production ontainment +equirements

    1:.Additional controls included for properduration or quantity.

    1

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    ?pdate pre"launch control plan (living document)

    AddF

    17ampling plans

    1ontrol method

    17P, inspection, attri'ute data and mistae"proofing

    1+eaction plan

    9onconformances clearly identified, quarantined and

    disposition made

    +equires customer approval unless otherwise

    specified +eference A!A* APQP +eference manual Appendi5 A"J, 6 and *

    Advanced Product Quality Planning143

    Production %alidationTesting

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    Engineering tests validate products manufactured

    withF1Production tools

    1Production processes

    1Production operators

    Performed under end"use operating conditions 2ultiple validationsfor multiple intended uses +eference Q7 D Element >.>.J

    Advanced Product Quality Planning144

    Production Trial +un

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    Production tooling, equipment,

    environment, facilities and cycle time

    Process instructions and control plans

    2inimum quantity set 'y customer

    (an 'e increased 'y team)

    *enerally = parts

    Advanced Product Quality Planning145

    Production Trial +un Product ?sed &orF

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    Preliminary process capa'ility studies

    27A (if not completed earlier) &inal feasi'ility

    Process review

    Production validation testing

    PPAP

    Pacaging evaluation

    &irst time capa'ility

    Quality planning sign"off #esign changes (if required)

    Advanced Product Quality Planning146

    Pp vs. p

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    In 1991, the ASQC/AIAG Task Force published the "FundamentalStatistical rocess Control" re!erence manual, hich shos thecalculations !or Cpk as ell as pk# These should be used toeliminate con!usion about calculatin$ Cpk# So hich %alue is bestto report, Cpk or pk& Althou$h the' sho similar in!ormation,the' ha%e sli$htl' di!!erent uses#

    Advanced Product Quality Planning

    (stimated si$maand the related capabilit' indices )Cp, Cpk, and Cr* areused to measure the potential capabilit' o! a s'stem to meet customerneeds# +se it hen 'ou ant to anal'e a s'stem-s aptitude to per!orm#

    Actual orcalculated si$ma)si$ma o! the indi%iduals* and the related indices)p, pk, and r* are used to measure the per!ormance o! a s'stem to meet

    customer needs# +se it hen 'ou ant to measure a s'stem-s actual processper!ormance#

    147

    Preliminary Process apa'ility 7tudies

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    haracteristics identified in the control plan

    ?sually : pieces minimum

    2ay 'e = if run is less

    Pp \ :.LK is accepta'le unless otherwise

    specified Pp ] :.LK requires action plan unless

    otherwise specified +eference A!A* &undamental 7P +eference 2anual

    1:. at spec limit

    1Z"= sigma O :.LK

    1Allows flop/ within spec limit

    Advanced Product Quality Planning148

    Process Analysis Animation

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    Advanced Product Quality Planning

    lsar$c&

    ourtesy of The Red Road

    httpF88www.sci.fi8^leo8149

    3istogram Animation

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    Advanced Product Quality Planning

    lsar$c&

    ourtesy of The Red Road

    httpF88www.sci.fi8^leo8

    150

    Process apa'ility Animation

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    Advanced Product Quality Planning

    lsar$c&

    ourtesy of The Red Road

    httpF88www.sci.fi8^leo8 151

    Process apa'ility Animation

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    Advanced Product Quality Planning

    lsar$c&

    ourtesy of The Red Road

    httpF88www.sci.fi8^leo8 152

    C ilit I t t ti C l i

    Process apa'ility 7tudies

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    Capaility Interpretati&n C&nclusi&n

    Pp V :.LK Process pro'a'lymeets customerrequirements

    urrent control plansufficient

    :.==UPpU:.LK Process may notmeet customerrequirements

    Additional controlsneeded until pV:.==achieved

    PpU:.== Process will not

    meet customerrequirements

    :Y inpection is

    needed until pV:.==achieved

    Advanced Product Quality Planning153

    Part 7u'mission 7tatus Possi'ilities

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    Advanced Product Quality Planning

    &ull Production Approval

    !nterim Approval1AuthoriGe shipment to #elphi

    without &ull Production Approval

    1orrective Action Plan is required.

    +eCected1orrected su'mission required

    'efore production quantities may 'e

    shipped.

    154

    !nterim Part lasses

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    Parts fromproduction tooling and

    require rewor to meet

    specs.

    CCParts not from

    production tooling, partsmeet specs.

    DDParts do not meetspecs.

    Parts do not meetspecs and vehicles with

    class E parts require

    retrofit to mae them

    salea'le.

    Advanced Product Quality Planning

    1 AAParts from

    production toolingand meet specs, not

    all PPAP

    requirements have

    'een met.1

    155

    P i i i l d f ll d

    +eview and 7ign"0ff

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    Process instructions in place and followed

    &low charts in place and followed

    *+$+ plans e5ist and are followed

    Pu'lish final feasi'ility report

    0'tain formal sigh"off

    7chedule and conduct management review

    0'tain management commitment to assist in

    open issues

    Advanced Product Quality Planning156

    ProCect Title ustomer

    Phase > ProCect +eview

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    2odel8Iear Part #ate

    0ur advanced quality planning team has considered the f ollowing questions in Phase >

    of our APQP process . The documents prov ided hav e 'een used as a 'asis f or analy Gingthe a'ility to meet all specif ied requirements. All 90 answers are supported with attached

    comments identif y ing our concerns and8or proposed changes to ena'le us to meet

    specified requirements.

    Ies 9o hec li st !tem

    :. 3as the production trial run 'een conducted and does it indicate the need for any changeH

    . 3as the produc tion part 'een approvedH-. 3as the production validation testing indicated any pro'lemsH

    L. 3as the evaluation of the pacaging of test shipments, where feasi'le, and test methods

    indicated any difficultyH

    K. 3as the control plan methodology chec list indicated any pro'lems with that documentH

    &easi'le Product can 'e produced as specified with no revisions.

    &easi'l e hanges recommended (7ee attached)

    9ot &easi'le #esign revision required to produce product within specified requirements

    Team 2em'er8Title8#ate Team 2em'er8Title8#ate

    Team 2em'er8Title8#ate Team 2em'er8Title8#ate

    Advanced Product Quality PlanningThis form is on course dis157

    Phase > +esponsi'ility2atri5

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    Phase 4I Pr&,uct an, Pr&cess Jali,ati&n

    2anageme

    nt

    Purchasing

    Engineering

    Quality

    )a'oratory

    7ales

    Production

    3+

    2aintenanc

    e

    2aterials

    2!7

    0utput

    Production Trial +un

    2easurement 7ystems Evaluation

    Preliminary Process apa'ility 7tudyProduction Part Approval

    Production %alidation Testing

    Pacaging Evaluation

    Production ontrol Plan

    Quality Planning 7ign"0ff

    2anagement 7upport

    Advanced Product Quality PlanningThis form is on course dis158

    APQP Phase -F &eed'ac, Assessment and orrective Action

    PlanningPlanning

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    Advanced Product Quality Planning

    The results of continuing production are evaluated for common

    or specialcauses of variationduring this phase to ensure that

    the products satisfy customer satisfaction requirements

    The effectivenessof the quality process should 'e evaluated

    during this process step

    1!ncludes continual improvement efforts

    1!ncludes delivery and service performance

    gg

    #esign $ #evelopment

    %alidation

    Production

    &eed'ac Assessment $ orrective Action

    aunch

    Product

    ProcessProduct " Process

    &eed'acAssessment $

    orrective Action

    159

    ontinuing Production

    ontinuing

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    Advanced Product Quality Planning

    Production

    #etermining

    0ngoing

    apa'ility

    ontinuing

    Production

    #evelop $ !mplement

    orrective Action Plan

    2easure #elivery $

    7ervice

    2easure

    ustomer

    7atisfaction

    p V

    or O :.==

    Attend ustomer Q07

    2eeting As +equired

    ontinuous

    !mprovement

    Plan $

    &eed'ac

    #evelop Q07

    2easurement

    #evelop #elivery $

    7ervice 2easurement

    Plan

    &r,:s Interpretati&n

    160

    + d d i ti

    Phase - 0utputs

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    +educed variation

    ustomer satisfaction

    #elivery and service

    Advanced Product Quality Planning161

    !d tif i ti

    +educing %ariation

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    !dentify process variation

    tae corrective action to reduce

    variation

    #evelop proposal for customer review

    *ain customer decision to implement,

    negotiate or change design

    Advanced Product Quality Planning162

    P d t i t f i

    ustomer 7atisfaction

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    Product or service must perform in

    customer/s environment

    7upplier must participate

    7upplier and customer must 'e

    partners +eference Q7 D Element >.:.L

    Advanced Product Quality Planning163

    4arrant

    ustomer 7atisfaction 2etrics

    stomer rating

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    4arranty

    a'our claims

    oncerns reports

    9onconforming

    material reports orrective actions

    0n time delivery

    Tech calls

    Advanced Product Quality Planning

    ustomer rating

    +eturns

    PP2

    +esponse time

    0n"siterepresentative

    2aret share

    ost control (totalcost)

    164

    ontinues the supplier customer partnership

    #elivery and 7ervice

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    ontinues the supplier " customer partnership

    in pro'lem solving and continuousimprovement

    +eplacement parts and services are

    important

    eads to possi'le price reduction fromF

    1!nventory cost reduction

    1Process cost reduction

    1ost of quality reduction

    1+eference Q7 D Element >.:-

    Advanced Product Quality Planning165

    Phase - +esponsi'ility 2atri5

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    Phase !I ee,ac#8 Assessent an, C&rrective Acti&n

    2anagement

    Purchasing

    Engineering

    Quality

    )a'oratory

    7ales

    Production

    3+

    2aintenance

    2aterials

    2!7

    0utput

    +educed %ariationustomer 7atisfaction#elivery and 7ervice

    Advanced Product Quality PlanningThis form is on course dis

    166

    Phase - ProCect +eview

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    ProCect Title ustomer

    2odel8Iear Part #ate

    0ur advanced quality planning team has considered the following questions in Phase -

    of our APQP process. The documents provided have 'een used as a 'asis f or analyGing

    the a'ility to meet all specif ied requirements. All 90 answers are supported with attached

    comments identif y ing our concerns and8or proposed changes to ena'le us to meet

    specif ied requirements.

    Ies 9o hecl ist !tem

    :. 3as a system for reducing future variation 'een developed and is it i n placeH

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    A!A* PPAP 2anual #efines +equirements

    APQP Product and Process %alidation

    7upplier su'mits PPAP to proper level

    PPAP pacage evaluated and status

    determined 7upplier and customer manufacturing site

    notified of PPAP approval status

    Advanced Product Quality Planning168

    A : #esign &2EA hec ist

    APQP 2anual Appendi5 A " hec ists

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    A": #esign &2EA hec ist

    A"< #esign !nformation heclist

    A"= 9ew Equipment, Tooling and Test

    Equipment heclist

    A"> Product 8 Process Quality heclist A"- &loor Plan hec ist

    A"L Process &low hart heclist

    A"K Process &2EA heclist